Printing plate and method of making the same



Oct. 23, 1928. 1,688,645

- E. E. 'NOVOTNY PRINTING PLATE AND METHOD OF MAKING THE SAME Filed Feb. 1926 4 Sheets-Sheet 1 Fig 7. 1

U \./r ML V M A \r Fi .2 2 v 1 VENTOR. BY I I i V ATTORNEYS.

Oct. 23, 1928.

E. E. NOVOTNY I Oct. 23, 1928. 1,688,645

E. E. NOVOTNY PRINTING PLATE AND METHOD OF MAKING THE SAME Filed Feb. 9, 1926 4 Sheets-Sheet 3 Fig. 6

YWZINV TOR. I BY I TORNEYS'.

Oct. 23, 1928. 7 I 1,688,645

- A E. E. NOVOTNY i PRINTING'PLATE AND METHOD OF MAKING THE SAME Filed Feb. 9, 1926 4 Sheets-Sheet 4.

- IYMVNYVTOR.

' Toma 5- Patented Oct. 23, 1928.

UNITED STATES I 1,688,645 PATENT OFFICE.

EMIL E. NOVOTNY OF PHILADELPHIA, PENNSYLVANIA, ASSIGNOR TO J'O HN STOG- DELL STOKES, OF SPRING VALLEY FARMS, HUNTINGTON VALLEY POST OFFICE,

PENNSYLVANIA.

PRINTING ILATE AND METHOD MAKING THE SAME.

Application filed February 9, 1926. Serial No. 87,111.

This invention relates to printing plates and the method of manufacturing the same.

Mymethod of-producing a printing plate is directed to the making of a structure which lacks homogenous qualities. I wish to have a printing plate dissimilar from the usual metallic printing plates in use at the present time in order to attain a product which may be curved and leveled without the usual distortion. As for example, when a plate which is first made in a fiat condition is subsequently curved, considerable distortion takes place and there is an un-uniform elongation, resulting in great difficulty from a dimensional and register standpoint. Furthermore, where the dimension in height to paper is either high or low in certain portions of the printing parts, it requires a more or less manual operation in order to bring these to the proper level and then with more or less distortion to the surrounding areas. My aim, also, is to produce, a printing plate such .as can be made by an inexperienced operator through the use of equipment which will utilize the inherent characteristics ofa printing'plate produced by my methods.

After long experimentation with Various eutectic alloys in the form of foil and plastic metal, I have discovered that an alloy such as, say, foundry type, monotype or other similar metals, even including mixtures of lead, tin and antimony, ismost useful for my purpose. These alloys when applied to a suitable matrix by means of ametallic spray properly adjusted form a structure which is not homogeneous and which apparently has had its particles combined through an alloy of lower melting point thrown out during the operation of the spray ing. This results in exactly the conditions most desirable for a satisfactory form of In other words, the printing plate is formed from a bath of minute metallic particles which are still in a somewhat plastic condition. These particles upon striking the surface, if the surface is properly prepared, are caused to deposit thereon, without rebounding there,- from, and form small, thin, scale like portions. These portions are apparently oxidized on their faces thus precluding the possibility of a solid, homogeneous welding acton. In addition to this, I have observed,

tained without actually This plate, when placed over a convex curved turtle heated to a temperature of approximately 400 F., took the curve of this turtle with a very slight amount of distortion and fitted the turtle perfectly. Upon cooling, while supported in this manner, the plate retained its shape and was immediately available for printing purposes. A plate made by casting as in the sterotyping art, using this same metal butproducing a relatively homogeneous plate, was next tested. It was placed in the same position under the same conditions on the turtle before mentioned and the plate did not curve and it would not curve of its own weight even after being heated to its -melting point.

Upon being heated to this high tempera: ture it collapsed and the entire surface of the printing plate was destroyed.

It can readily be seen that by using proper turtles suitable curves can be made and that there will be a minimum amount of stresses and strains on a curved plate of this kind. To emphasize the point still further, it might be stated that both a commercial electrotype and a commercial stereotype were substituted for the stereotype made of foundry metal and that a suitable curve could not be obsoftening or melting the entire body of suc plate. A

In leveling to a standard height to paper it is quite apparent that if we provide a suit-, able level base, lace the plate face down on such base an heat to the point where plasticity occurs, the plate will seek its ownlevel without melting and without undue distortion. 'Of course, a slight amount of pressure is always desirable for both the leveling and curving operations, and there fore I provide a light pressure for this purpose.

For my purpose a matrix made of a plastic, waxy, fusible material is'most suit able. The matrix material can be melted out 20 or prefera as a higher temperature.

advantage for the sprayed plate inasmuch as it is necessary to provide a suitable adherent surface which will hold the sprayed particles whenthe first are applied to such matrix surface. his is extremely important inasmuch as otherwise the s rayed particles could not be evenly applied against such surface. A lar e portion of these would rebound upon impact, with the result that an even, highly polished reproduction would not result vIn order to .use a waxy matrix having a low softening point it is essential to provide a suitable cooling means either between subsequent-applications of thin sprayed films 1y immediately following the area being sprayed in order not to unduly soften or distort the delicate maxtrix face.

This I provide b means of an air nozzle which follows in t e path of the spray nozzle and removes with rapidity a large portion of the heat carried by the sprayed particles and by the heated air if it is used. I prefer at times to humidify the-air in order that agreater and quicker cooling action may then be secured.

I It is quite desirable at times to reproduce work from matrices such as those of the lead mold type or such as thosemade in papiermach or other materials capable of standing This is true in the case of reproductions of fine etchings, 'etc., and a better resulting product is often obtained by the use of a matrix of this type where the electrotyping process is followed.

" In following out my process it will be readily noted that a graphitic coating to insure conductivity need not be applied to the'wax matrix and therefore the reproduction from wax will be fully up to that obtained from the lead mold. Commercially, however, lead molded work is in demand and I provide a means for the use of non-waxy matrices by the application of a thin film of wax or Canada balsam to the surface of such matqo, rices in order to provide a footing for the s rai ed particles being applied thereon.

s t ese products are applied in a very thin solvent solution they do not affect the fidelity of the reproduction but are present in suflicient quantity to give the sprayed plate 0 the edges of such metallic base in order to obviate any possibility of the wax matrix curving or sagging during the application of the spray. This provislon is an aid to the production of plates having the same dimen- 05 sions of the printing parts in height to paper as the original matrix distorting,

thereby stretching and giving dimensionalerrors throughout the printing area.

.The use of alloys such as those mentioned is very desirable where a plate havin the plasticity before mentioned 1s wanted. It is, therefore, to be understood that I may make my plate of any sprayable material or metal which will be suitable for my purpose. For certain cheap advertising plates it does not matter greatly whether there is a variation inheig'ht to paper andv therefore it may be desirable to produce a plate usin cheaper materials. or using materials llghter in weight, say, for example, aluminum. However, it will be found that even Where these materials are used the method described by me of providing a matrix having an adherent film will be most suitable for this urpose where a fine reproduction is desired? A fine metallic'spray is essential for the face forming portions of the printing plate.

This is obtained by setting the air and metal outlet nozzles close to ether. A fine spray, however, can be app ied but slowly, and therefore, from a commercial standpoint, it is preferable to have more than one nozzle in or erthat a fine spray may first be applied and that this be followed by a coarse, quickly a plied body or backing portion. With the a ustable nozzle I employ, one nozzle can be used for both purposes as by operating upon. a batch of matrices first to ap 1y a facing coat; these matrices with their acing coats may be operated upon later with the nozzle adjusted for coarse spray to secure a thick backing section more quickly. Likewise, a plurality of finely adjusted spray nozzles" may be used, and if desirable apluraligy of coarse spray nozzles can also be use The fine spray portions may be composed of different alloys or, for that matter, formed of 'a tough wearing material such as, for.

example, aluminum, copper or nickel, and

spray and a coarse spray application, or, in some instances, the fine spray backing may be omitted.

' The application of tougher films to the face may be done by subjecting the sprayed plate toa subsequent electrolytic deposit. This harder face backed up with a non-homogeneous metal offers advantages such as are not present in the solid homogeneous metal plates when it comes to a leveling and curving operationz The face section is hard and not readily damaged through pressure against a level surface plate, whereas the body portion when heated well below its melting point will assume a plastic condition without melting and Without lateral elongation or distortion. This protection of a harder face, whether applied by a spray or subsequently by means of an electrolytic deposit,'while being useful in giving longer Wear to the finished printing plate also helps to prevent the 'marring of a delicately ornamented printing surface.

The printingplates made entirely of type founders metal having at first a fine sprayed facing section backed up with a coarse sprayed backing section were given an en--' durance test in actual high gr de printing on coated sto ek. These plates ave shown a production under actual printing conditions of over 300 000 high gradeimpressions. This test shows conclusively that these plates are capable of standing long runs. It is, considered a very good production to secure 250,000 impressions from a nickel faced electrotype' V In the accompanying draw'ings Fig. 1 shows a crosssectional view of a wax matrix supported in a suitable pan.

Fig. 2 shows a cross sectional view of a lead matrix having a wax coatingapplied thereon.

Fig. 3 is a perspective view showing the apparatus in position to be employed in spraying against the face of a suitable matrix.

Fig. 4 is a cross sectional view showing a printing plate made by my method wherein a fine facing spray is first applied and being subsequently backed with a coarser sprayed body forming section.

Fig. 5 is a cross sectional view of a modified form of printing plate similar. to that shown in Fig. 4 withthe exception, however, that a harder face coating is applied either by means of a spray or by a subsequent electrolytic deposit.

Fig. 6 is a perspective view showing the apparatus and plate in position for leveling.

'Fig. 7 is a perspective view showing the apparatus used and printing plate in position thereon after having been curved.

In operating my invention ll produce a suitable matrix as shown in Fig. 1 and indicatedas an entirety by M. This-matrix blank is first formed by pouring a suitable wax-like composition 1 into the pan P. The impression is taken in this wax in any well known manner, the face forming portion being indicated at 2.

Another form of matrix used for this pura suitable movable carriage O, traveling upon tracks T. This carriage gives both longitudinal and transverse motion by means of the arms 5 and 6. This provides a suitable means for maintaining a relatively fixed dis- .minating in the leads indicated at 7. When foundry type metal is used this has a melting point of approximately-650 F. and it is preferably heated to a temperature not to exceed 850 F. The molten'meta'l is controlled by means of a plug valve indicated by the screw and knob terminus thereof at 8. The metal issues from the nozzle S, 'the nozzle being sufiiciently heated by the excess heat carried by the metal and is vaporized into a fine spray by the air nozzle A Which is made adjustable by means of the adjustment device indicated as an entirety at 9, a supply of heated air being conducted thereto by pipe 10, the heating of the air being accomplishedthrough the use of the heater shown as an entirety at H consisting of coils 11, operating in the zone of a suitable source of heat as at 12. The nozzle S I find should have an opening not greatly exceeding a diill ameter of .020" whereas the nozzle A for the air is considerably larger but preferably should. not greatly exceed a diameter of 070"."

It will be noted by reference to Fig. 3, that molten metal flows from the melting pot by low gravity, and therefore the liability of the particles striking the matrix and rebounding,

or being welded together in a homogeneous mass, as would be the case with removing the .molten metal from the pot under pressure,

is avoided. v

A suitable cooling'means is provided as by means of the cold air nozzle A connected to the pipe 13, and if at times a small amount of water-is useful this is provided by means of the water nozzle W termin'atingin the pipe 144.

The spraying apparatus in Fig. 3 is suitably hooded as by means of the hood conventionally shown at H terminating in a suction fan opening indicated at 15 which may be at either the top or the bottom of pose is made of any high melting point mathis hooded device, suitabledoors being proterial such as'the lead mold or matrix shown in Fig. 2 and indicated as an entirety by M. At 2, 1 indicate the face forming portion of such matrix, and the application of .the adherent or waxy material at 3. This waxy material may consist of a weak solution of say beeswax or Canada balsam, a suitable solvent being used. Fig. 3 shows the apparatus in its simplest form, illustrating the method of operatingvided at 16. The lower section of this hood H serves to retain any dust particles which may settle and which may not be removed through the opening 15 by means of the fan and cyclone receptacle (not shown), this cyclone receptacle serving to deposit any metallic particles which may be carried over by the air in a manner already well known.

In Fig. t I show the completed plate indicated as an entirety by P. This printing v upon the mat-rix'lvl which is supported upon. plate consists of a facing'of finer sprayed polished face 18 and the coarser sprayed or less homogeneous particles forming the back- I ing indicated at 19. The back portion of such plate has been roughly shaved and is indicated at 20. I

Fig. 5 indicates a printing plate very similar to that shown in Fig. 4 wherein the printing plate again is indicated as an en tirety by P. The printing face indicated at 18 consists of a tougher metalwhich may be either applied as a spray or which may be applied subsequently as an electrolytic coating. This may be followed optionally with the finer sprayed facing section 17 and the coarser sprayed backing section 19, the back thereof being again shown at 20.

In Fig. 6 I show the leveling apparatus indicated as an entirety by L supported on a suitable stand or base. This leveling device L consists of a level surface plate section S which is heated as conventionally shown by the gas cock at 21. this base is so heated that the plate will quickly assume a temperature of approximately 400 to 500 F, the plate lying with its face 18 against the polished surface plate S, and proper pressure is applied as by means of the screw 22 operating against the platen 23. A suitable resilient blanket (not shown) is preferably placed between the back ofthe printing plate 20 and the lower section of the pressure platen 23, in order that a light pressure may be applied and that any irregularities may be taken up in this blanket. A suitable cooling means is provided as by means of the inlet hole 24 and outlet hole 25, for the admission of cooling water in order thatthe plate maybe quickly cooled. by circulating cooling water in a properly cored cooling plate. I

In Fig. 7 I show an apparatus conventionally shown for the purpose of curving my sprayed plates. This apparatus is indicated as an entirety by B which is supported on a suitable base. This curving apparatus consists essentially of a heating base indicated as an entirety as S, having a polished curved base section 18 suitably heated as conventionally shown by the gas cook 21. Pressure is applied by means of the screw arrangement 22 operating against the concave polished platen 23 against the face of the printing plate 18, the back of which is indicated by 20. Suitable cooling facilities are again provided as for the leveling apparatus by means of the openings to the cored out section of the base S wherein 24indicates the inlet for cooling water and 25 an opening for a suitable outlet. The plate is placed face up upon the heated platen S, until the desired temperature is reached. This for foundry type metal will be between 400 and 500 F. .It will be found that the plate has assumed its curved form and that As stated previously,

for by the concave section 23 and convex section 18'. For some purposes a resilient blanket (not shown) may be interposed be- I tween the back of the plate 20 and the convex section 18' in order that irregularities may be taken up.

It will, of course, be understood that instead of producing ordinary relievo plates by this process, I'may produce intaglio plates by the use of suitable originals or by means or ordinary expedients such as, for example,

lnversion.

While I have herein shown and described certain preferred embodiments of my inven tion, I wish it to be understood that I do not confine myself to all of the precise details herein set forth, as modifications and varia tions may be made without departing from the spirit of the invention or exceeding the scope of "the appended claims.

Although I have stated in the preceding portion of the specification that the air nozzle A is furnished with a supply of heated air by being conducted through pipe 1( and through heater' coils 11, it should be understood that in certain cases it may be possible to dispense with the heating of this air, in which case the source of heat 12 may be merely. omitted. Using certain metals or alloys capable of absorbing a certain amount of superheat, this may be suflicient to produce a fair grade of sprayed work without the use'of the hot, dry air. The dimensions for the nozzles S and A should be provided with suitable openings to take care of the type of metal used. Where the dimensions given are for type founders metal, other alloys or ,metals may require certain variations in these dimensions. However, it will be found preferable in all cases to have the nozzle A of larger diameter than the nozzle S.

What I claim isp 1. A printing plate having a non-homogeneous type-forming face of sprayed metallic particles.

2. A printing plate having a non-homogeneous type-forming face of sprayed me-, tallic particles and a suitable support or backing for the face portion.

8. A printing plate having anon-homogeneous type-forming face portion of sprayed metallic particles and a backing portlon also composed of sprayed metallic particles.

4. A printing plate having a non-homogeneous type-forming face portipn of sprayed particles of a metallic alloy, and a backin portion forthe face portion.

5. A printing plate having a porous nonhomogeneous printing face of fine sprayed metallic particles, and a backing portion cles.

therefor of coarser sprayed metallic parti 6. A printing plate composed of nonhomogeneous sprayed metallic particles having a printing face surfaced with a film of hard, wear-resisting metal.

7. The herein described method of making a printing plate which comprises subjecting a gravity flowing streamof molten metal to the action of an air blast to impinge the metal in the form of a finely divided spray against the reproducing face of a printing plate matrix, and continuing such application until a printing plate of predetermined thickness is formed.

8. The herein described method of making a printing plate which consists in depositing upon the reproduction face of a printing plate matrix, sucessive films of molten metal applied in the form of-a. spray, said metal being so constituted that the printing plate may be flexed when heated below themelting point of the metal. I

9. The herein described method-of making a printing plate which consists in subjecting a suitable matrix to a spray of metallic particles to produce a relatively thin non-homogeneous metallic deposit forming a printing face, and then making a subse quent application of sprayed metal until a plate of suitable thickness is produced.

10. The herein described method of making a printing plate which consists in subjecting a suitable matrix to aspray of metallic particles to produce a relatively thin non-homogeneous metallic deposit, cooling said deposit, and then making subsequent applications of sprayed metal until a nonhomogeneous metallic plate of suitable thickness is produced.

11. The herein described method of making a printing plate which consists in spraying molten metal against a suitable matrix -to produce a non-homogeneous metallic printing plate face portion, and then making subsequent applications of sprayed metallic particles to build up abacking portion of suitable thickness.

12. The herein described method of making a printing late which consists in exposing a suitab e matrix in the zone of a metallic spray to form a non-homogeneous metallic printing face and body portion, and subsequently depositing, electrolytically, a tough wear-resisting metallic film on. the

' printing face of said plate.

13. The herein described method of making a printing plate which consists in depositing upon the matrix, having its reproducing face coated with a wax-like sub stance, molten metal in the form of a spray to form a non-homogeneous printing plate face, making subsequent applications of the metallic spray to build up a printing plate body of suitable thickness, and cooling the metal of the plate between applications.

14:. The herewith described method of exposing a portion of a suitable matrix in the zone of a metallic spray, applying a thin metallic coating while moving the metal coated matrix portion toward the zone of a cool air nozzle to quickly cool the metallic film previously applied.

15. The herewith described method of making a printing plate which consists in exposing a portion of a suitable matrix in the zone of a metallic spray, applying a thin metallic coating on a portion. of,the matrix or printing plate being formed while simultaneously moving the coated portion in the direction of the cooling zone of cool moist air to quickly cool the metallic film previously applied.

16. The herein described method of making a printing plate which consists in spraying heated metallic particles against a suitable matrix to form the printing plate while employing heated air to prevent the premature chilling of the metallic particles during the spraying operation.

Signed at Philadelphia, in the county of Philadelphia, and State of Pennsylvania this 5th day of February, A. D. 1926.

EMIL E. NOVOTNY.

'making a printing plate which consists in 

